Semirefractory heat insulating material and method of making the same



Dec. 30, 1 1,520,893

C. S. TEITSWORTH SEKIREFRACTORY HEAT INSULATING MATERIAL AND METHOD OF MAKING 'THE SAME Filed Dec. 1, 1925 lDrye r a steam al 2/2 'F Indurml'or 12' I4 INVENTOR 4 Clark Bifsrrarib ATTORNEY Patented Dec. 30, 1924.

UNITED STATES PATENT" OFFICE.

CLARK s. mnrrswonm, 0e LOMPOC, CALIFORNIA, AssIeNon'To THE cnLrrE ooivrrnmr,

or LOS ANGELES, CALIFORNIAVA CORPORATION or DELAWARE.

SEMIREFRAGTORY HEAT INSULATING M ATERIAL AND METHOD OF. THE SAME. i

Application filed December 1, 1923. Serial No. 678,030.

To all whom it may concern:

' Be it known that I, CLARK S. TEITSW RTH, a citizen of the United States, residing'at Lompoc, county of Santa Barbara, and

State of California, have invented a 'new manufacturing an engineering construction.

material having refractory and heat insulating properties and at the same time those qualities which give permanency, light weight, and freedom from disintegration, shrinkage and spalling at high temperatures.

Of the many materials used in the manufacturing of heat insulating compositions, magnesiumcarbonate and diatomaceous earth have been the most generally adopted- Compositions containing magnesium carbonate have several disadvantages, namely, the block or form made therefrom shrinks and checks badly at temperatures above 1000 F; so that almost complete disintegration'takes place. This is due to the liberation of carbon dioxide from the'carbonate. Diatomaceous earth, however isthe most efficient heat resisting and insulating mate rial in the naturalstate which has'yet been found and many methods of binding the particles of the earth so as to give the desired strength without reducing the heat insulating properties have been tried and abandoned as unsuccessful. a i

The present invention is an important improvement upon the art in that I have devised a method of manufacture by which a.

very small amount of binder produces a material having great natural strength and cohesion and at the same time better heat insulation ability than the natural diatomaceous earth in compacted state.

It has been, well-known that silica and lime in the presence of steam at a pressure of approximately 150 pounds, will combine to form. calcium silicate resulting inhard and horny mass, having a high crushing strength. My present invention obviates the use ofhigh pressures and forms calcium silicate at atmospheric pressure which ,binds and holds together the particles of diatomaceous earth without destroying their 11 .vening plate.

structure or impairing their value as heat insulators i f 1', .The accompanyingfdrawingsillustrate an apparatus suitablefor carrying out my invention i ring thereto V Fig. 1 is a'diagrammatic elevationof such apparatus. i f v 'lFim 2 is a horizontal section of two of tie The apparatus shown in the drawings comprises an agitator, or mixing tank 1, provided with mixing arms 2 operated by any suitable means'and further provided if necessary with a steam jacket 3 for heating the same. A meansindicated at 4 is provided for feeding to the tank 1 the composition to' be mixed. Tank 1' is provided at its bottom-with an outlet 5 leading to suitable forcing .means, .for example, an

air pressure tank or monte-jus 6 which is adapted to force the mixture throu h a ipe 7 to a filter press or apparatus 8. aid lter press may be of the usual plate and frame type, being constructed of -remov-.

able forms having permeable membranes which retain the particles and fibrous.ma-:

te'rial which compose the block orshape formed in thefilter press. These forms may vary in size and are easily set up. Theframes are made of dimensions, corresponding to the block of composition which is to be formed and each frame 9 with its permeable walls indicated at 10 in Fig. 2 forms a filter mold. The apparatus further comprises an indurating or hardening kiln or chamber indicated at 12 and a drying chamber indicated at 13. Suitable cars 14 and track means therefor may be provided for conducting the blocks gradually through said indurating kiln and then through said dryingv chamber. The air pressure tank 6 vmay be provided with air supply means-18 for maintaining air pressure there n and for agitating the mixture. By opening valve 15 in the outlet of-tank 1 and also opening air referred: form', andjf'refer filter molds, or frames with theinterexhaust valve 16 for pressure tank'fi, the

mixture may be discharged from tank 1 into tank 6 and then by closing valves 15 and 16 and opening a valve 17 in pipe'7, the mixture maybe forced by air pressure to the filter press 8.- y

The composition which I have found forms are filled the blocks are removed,

for the. reaction of lime and diatomaceous into molds. In any case, 1 induced after shaping, by maintaining mass at an elevated temperature, as in chamber or suitable in many cases consists of by the steam so as to produce any superweight of finely divided or disintegrated atmospheric pressure. For convenience the diatomaceous earth, 15% lime, and 10% asblocks or slabs formed in the filter press may bestos fiber. The finely divided diatomabe placed on cars which are passed through ceous-earth, quick lime, and fiber are-thortheindurating kiln and the drier so that oughly agitated in form 8 to 12 parts by the blocks arefirst subjected to an induratw'eight, of water which has been warmed up ing or hardening operation and then dried originally to about 120 F. and in addition to any desired extent.

has been heated by the reaction of the quick- It hasbeen possible for me to manufacture lime uponhydrating. Upon agitating the blocks of various sizes for heat insulating required amount of-time, usually not over purposes by the use of the above described two hours, the slurry is forced by air pressure or other suitable means into a filter gave press containing forms having thegexact Y K dimensions. of the desired finished block. condltlons th an any other blocks now found Pressures of not over 25 lbs. per sq..' in. are on the market. Upon testing these blocks used in filtering the slurry and after thethey showedalmost absolute freedom from carbon dioxide or carbonates and after exand posure to 1600 F. showed a shrinkage of only a little over 1%. Their heat conductivity was below that of diatomaceous earth found in its natural state.

a higher resistance to heat flow and placed upon steel drier cars or pallets induratedin a steam chamber atatemperature of about 212 F. and at atmospheric pressure for a period of three to six hours. The blocks are then-.passed through a tunnel or drier having a maximum temperatu f not, v 500 F, d ll excess oi dlatomaceous earth in the kettle or agitator ture driven. off. This processproduces 1, add thereto from 3 to 4 parts of water blocks varying in density from 15 to 22 lbs. and after thoroughly agitat ng, feed in per cubic foot. slowly by we ght, of quick lime in a That feature of my invention which confi ly dlvlded 0011(11131011'; .1 asbestos fiber sists in mixing'the lime, diatomaceous earth, 18 then added and the agltation continued fib r, nd w t a d ing for a, hort until ahomogenous mass 1s obtalned, usually time before charging to the filter press h highlyimpo'rtant. If the mixture is made entire operation. This mass is then poured in the cold and not warmed before filtering into molds, trowelled over the surface to out the excess water, the cakes formed in givea smooth finish and the filled molds the press are dense and give on drying. If, on the other hand a part although no pressure is exerted, a temperaof the lime is combined with the silica, warming previous to filter-pressing, there is process is 'continuedfor 8 hours and the caused sufficient swelling of the mass to give blocks then removed from molds, trimmed lighter filter cakes and a less dense product or sawed to size and placed in a drying after drying such cakes. By this invention, oven or tunnel, where all excess moisture is it is possible to control at will, within rather driven off. The resultant block may vary wide limits, the density (and consequently I from 12 to 17 lbs. per cubic foot in weight the insulating. power) of the product, by and may be used for heat insulating of-all simply choosing a suitable period of time high temperature, equipment.

Although quickl'me in a finely divided earth in thehot mix, previous to shaping condition has been found tobe more reactive, in the filter press. The same process of pre and under. one form of operation ..has proliminary swelling may be used also, if the xiueed blocks having a higher crushing shaping is to be done by simply pouring strength than those made by the use of the final set' -is hydrated lime, I do not wish to limit my the invention to the use of lime inthe form the of an oxide alone- The asbestos fiberg used in this. composition gives the bloc s an added degree of strength at low temperatures, that is temsteaming chamber described below, for several hours; v

The indurating operation above referred to is carried on in substantially atmospheric pressure and of a. above this limit the fibers are greatly temperature of about 212 Fj.,the indurating weakened and practically a burnedv out at kiln 12 being formed, for ex 1400 F. At this temper'ature,'however, the ample, as a tunnel kiln and provided with blocks develop some strength by the action means for closure at the ends thereof by of heat'upon the particles of diatomaceous doors or the like so as to retain the heat and earth and calcium hydro-silicate, so "that steam within the kiln but without confining there isno disintegration or weakening when equipment which were lighter in weight,

remained more constant; under extreme heat As an alternative method of manufacture, I may place the required amount of.

i' rnot over an hour being required for thea heavy block placed in a chamber filled with steam so that by ture of 212 F. is maintained. This curing the presence of steam at peratures which do not exceed 1000 F., but

low pressure steam drums, sweating tempgratures, etc., the use of asbestos fiber may dispensed with and a cheap manila or cellulose fiber substituted therefor.

Moreover, for low temperature Work I have found itdesirable to Waterproof, or coat the blocks so as to make them water repellent. This may be accomplished in many ways, with a great many substitutes, either by treating the uncombined particles of diatomaceous earth, or the finished block,

and since the method of Waterproofing is Well-known, it is' unnecessary for me to describe this operation in detail.

For some work where large blocks of insulating construction material ,are desirable, such as insulation of oil or gasoline storage tanks, I have found that the insertion of a strip of Wire mesh through the center of the block adds materially to its strength, it is then possible to bend a block in order 'to'make it follow the contours of a-tank or other equipment, Without the formation of cracks or breakage of the block. Bending may be facilitated by sawing a kerf or multiplicity thereof in the concave side of a block so as to take care of the compression of-vthe material forming the .block. In forming such reinforced blocks by the filter mold method, the wire mesh is suspended in the center of the forms and the block built up around it. .Blocks may also be molded only half the thickness beingpoured. first the wire mesh laid on and the second half poured on top;

In using the 'monte-jus or pressure tankshown at 6 in Fig. 1 either steam or air may be used 'forproducing pressure and I agitation, the said device operating as an air or 'steam agitator by introducing the air or steam at the bottom of the tank, possibly by extension of the air inlet from the top. When filling the press, pressure is built up in the tank to the desired value, the thin slurry being agitated in the tank while the pressis being filled.

What I claim is: i. 1. The methodof'makinga heat insulating composition which consists in subject ing a mixture comprising diatomaceous earth and lime to the action of heat and agitation in the presence .of water, then molding the mixture to desired shape and subjecting the molded material to the action of steam at substantially atmospheric pres- This is' For work which does not require sure to indurate the material and subjecting the indurated material to a drying operation. v.

2. The method of making a heat insulating composition which consists in subjecting a. mixture comprising diatomaceous earth and. lime together with water to the action of heat and agitation at a sufficient temperature and for a sufiicienttime to cause an increase in volume of the solid material and to cause partial reaction between the lime and diatomaceous earth to form a voluminous calcium silicate, molding the material so produced .to desired shape, subjecting the molded material to induration to complete the reaction between the lime and the diatomaceous earth, resulting in the formation of calcium silicate and then drying the molded and indurated material.

3. A process as set forth in claim 2 in which the indurati'on is effected by subject ing the material to the action of steam at substantially atmospheric pressure and at a temperature of approximately 212 F.

.4. The method of making a heat insulating composition which consists in mixing diatomaceous earth, quick lime, and water, 7

subjecting the mixture toa cooking operatlon by the action of heat and agitation, to cause a permanent lncrease in volume of formation of calcium silicate, such heat being produced in part. by the slaking of the the solid material thereof, and partialterial, subjecting the mixture to a cooking operation by the action of' heat and agita tion in the presence of water tocause a permanentincreasein volume of the solid material thereof and partial combination of the lime and silica, then molding the resulting product, subjecting the molded material to induration to complete the reaction between the diatomaceous earth and ',lime,- and then drying the molded indurated material. I

6. A method of mpking heat insulating bodies which consists in mixing 7 5 per cent mixture to a cooking operation by the action of heat and agitation in the presence of water to cause a permanent increase in volumeof the solid material thereof and partial combination of the lime and diatomaceous earth, then molding the resulting product, subjecting the molded material to induration to complete the reaction between the 'diatomaceous earth and lime and then drying the molded indui'ated product.

7. A heat insulating composition consisting of the product of mixing diatomaceous earth, lime, and fibrous material, subjecting' the mixture to a cooking operation by the action of heat and agitation in the presence of water to cause a permanent increase in volume of the solid material therevember 1928.

tion to complete the reaction between the diatomaceous earth and lime, and then drying the molded indura-ted material. In testimony whereof have hereunto subscribed my name this 19th dayoof No- CLARK e. TEITS-WORTH. 

